All posts by Pierre-Yves Schmid

Powerful solution for three- to five-axis precision machining

With the Picomax 75, Fehlmann announces a powerful solution for three- to five-axis machining. The machine construction, the Z-axis travel, the geometry and the control unit are designed for five-axis operation with the company’s dividing and swiveling units.

The robust Picomax 75 is designed to increase efficiency wherever the highest precision and highest machining performance are called for.

Up to five axes are fully integrated in the control system. This combination is said to ensure optimum access and precision in five-, four- and three-axis machining. The Picomax 75 can also be ordered as a pure three-axis milling machine, whereby fourth and fifth axes can be retrofitted if required at any time. As is pointed out, the machine is easily accessible from the front, also in combination with the optionally available automatic parts handling.

At EMO Hannover 2017 the exhibit will be equipped with a six-axis articulated-arm robot to enable the handling of blanks without pallets. Thanks to the automatic, flexible re-clamping of parts by the robot, an all-over machining of workpieces is possible without operator intervention. Workpieces can be produced with fully automated manufacturing and emerge completely finished from the machining process.

Tornos continues to perform well

The Tornos Group performed very well in the first half of 2017. After a somewhat sluggish start to the year, demand for all product lines picked up significantly in every region from March onwards.

The Tornos Group improved all the key business figures in the half-year financial statements markedly. Order intake for the first half of 2017 was up by a total of around 65% on the figure for the equivalent prior-year period (and even by 98% in the machines business), the backlog rose by around 75% compared with the end of 2016, and net sales were also considerably higher than in the same period of the previous year. Tornos is back in profit with EBIT of CHF 1.7 million and a net result of CHF 0.3 million. The Group expects the annual financial statements to show positive EBIT and a positive net result. In the first half of 2017, the Tornos Group posted total net sales of CHF 82.1 million (first half of 2016: CHF 69.8 million, +17.5%) and order intake of CHF 103.2 million (first half of 2016: CHF 62.6 million, +64.7%). In the machines business, Tornos even managed to increase order intake by 98%. The operating result (EBIT) for the first half of 2017 came to CHF 1.7 million (first half of 2016: CHF -2.4 million), and the net result was CHF 0.3 million (first half of 2016: CHF – 3.5 million).

In the first half of 2017 the Tornos Group generated positive free cash flow of CHF 10.1 million, thanks partly to a substantial reduction in net working capital since the start of the year. The Group had experienced a cash drain of CHF 9.1 million in the first half of 2016. The number of people employed by the Tornos Group (in full-time equivalents) rose slightly, from 631 at the end of 2016 to 641 at the end of June 2017.

Market position improves considerably
Streamlining and expanding the product range enabled the Tornos Group to strengthen its position considerably in the various market segments and regions in the first half of 2017. Order intake improved markedly in all regions. During the past year, the automotive industry – the most important market for Tornos – suffered from uncertainties and great reluctance to invest. Confidence returned to this market in the first few months of 2017 and demand for capital goods increased sharply, especially in the higher-price segment. The market segments of medical and dental technology and electronics also saw demand for high-value capital goods increase significantly in the first half of 2017. It is only in the watchmaking industry that no turnaround has yet been perceived.

Demand for high-end products rises strongly
Having already boosted sales of machines in the medium-price segment in the second half of 2016, the Tornos Group achieved very gratifying sales in the highend multispindle segment in the first half of 2017. This was largely attributable to the newly launched MultiSwiss models, which can be used for manufacturing parts with a diameter of up to 32 millimetres. In June 2017, Tornos delivered the 200th machine from the MultiSwiss range, which was launched in 2011. Tornos also intends to add extremely innovative high-end machines to its Swisstype automatic lathe (single-spindle) product range. These will be unveiled to an interested specialist audience at EMO Hannover, the industry’s leading trade show, in September 2017.

Systematic implementation of the flexibility strategy
As part of its flexibility strategy, the Tornos Group began outsourcing a substantial portion of component manufacture to third parties at the beginning of 2015 via targeted global supply chain management. These activities will be stepped up in the second half of 2017. At the same time, the Tornos Group will invest in ultra-modern manufacturing technologies in order to be able to produce its key components and small series more efficiently.

Outlook for the second half of the year
The overall economic prospects and the forecasts for the Swiss mechanical engineering industry are all positive for the second half of the year. Thanks to its streamlined product range which is ideally tailored to the needs of its customers, Tornos is well equipped to continue to benefit from the revival in demand in the core markets. The Group also expects positive EBIT and a positive net result for
the 2017 business year.

Joint Venture Römheld Rivi pools competencies

At the Fakuma, the newly established Roemheld subsidiary Römheld Rivi GmbH presents itself for the first time to a broad specialist audience. The new company pools competencies and activities of the Roemheld Group around the magnetic clamping technology. Besides the introduction of the company, the focus of the fair presentation will be on magnetic quick-clamping systems for plastics and rubber processing that are also suitable for high-temperature processes.

At Stand 1223 in Hall A1, the company presents the diversity of M-TECS magnetic clamping plates which can be used for working temperatures of up to 240°C. Thus, besides the application for injection moulding, also processing of rubber and high-tech thermoplastics as polyetheretherketone (PEEK) or polyphenylene sulphone (PPSU) is possible, where conventional magnetic clamping systems fail in the long run. So far, Römheld Rivi is the only company worldwide that offers magnetic clamping plates for such temperatures.

Quick clamping of different mould geometries and weights
For clamping and releasing, the magnetic clamping systems require only a short current pulse, in operation, they work without any power supply. Permanent magnets generate a magnetic field that penetrates a few millimetres deep into the mould and hold even heavy mould halves weighing several tons in the correct position and bring them together absolutely parallel. Thus, also elements with complex geometries can be exactly clamped without deformation within seconds. A further advantage of magnetic clamping systems is their flexibility: moulds of different sizes, weight and geometries can be clamped, a standardisation of the moulds is not required. All magnetic materials are clamped on the full surface and with a high bending stiffness. The uniform distribution of the clamping force ensures a low mould wear.

Processing of high-performance plastics
From the magnetic clamping technology benefit amongst others processors of thermoplastics such as PEEK that is used for example as sterilisable and biocompatible material in the medical technology, as flexible circuit carrier for electronic components or as heat-resistant material in the aerospace industry. In continuous use, the high-performance plastic can be used at temperatures up to 260°C; the smelting process only starts at approx. 335°C. This results in high mould temperatures during processing that create the need for appropriate clamping means. Magnetic clamping plates of the M-TECS series which are already used for more than a decade in the rubber industry at working temperatures up to 240°C are applied as quick-clamping systems. The size and shape of the magnetic clamping plates can be customised to the requirements of the client. Heating for high-temperature processes can be integrated. Since a clamping system consists only of a few components and has no moving parts, it can be retrofitted within a few hours on existing machines and then the system is in principle maintenance-free.

New subsidiary Römheld Rivi intends to develop the technology
To develop the magnetic clamping technology – among others for Industry 4.0 applications –  Hilma-Römheld has founded together with the Italian manufacturer of clamping means and long-term partner Rivi Magnetics S.r.L. the Joint Venture “Römheld Rivi”.

Roemheld: Optimizer of set-up times for plastic and rubber processing
With an extensive portfolio of mould and die clamping technology, the optimizer of set-up times Roemheld solves almost any clamping technology task in plastic and rubber processing. The magnetic, hydraulic and electro-mechanical clamping systems are highly versatile and contribute to make processes in single and series production more efficient and economical. Products for mould/die change such as die changing cart, media couplings, roller bars and carrying consoles complement the product range.
The ROEMHELD Group stands for solutions that contribute to a more efficient and economical design of the processes in the single and series production of nearly all industries. With innovative products of the production, assembly, clamping and drive technology, the group of companies is one of the international market and quality leaders of the industries concerned. Elements for production, testing and maintenance of large-scale components for wind power plants, components for the automation of setups and machine communication within Industry 4.0 complement the portfolio. The activities around the magnetic clamping technology are grouped together in the Römheld Rivi GmbH founded in 2017.

Tool, pattern and mould makers have a home

763 exhibitors, 14,000 visitors: 2nd edition establishes Moulding Expo as the international marketplace for an innovative industry

Stuttgart proved to be the perfect stage for the topics in                    the industry
Thomas Seul, President of the Association of German Tool and Mould Makers (VDWF): “MEX is characterised by a very special ‘spirit’. The profile of the trade fair in the industry is very pronounced. Tool makers came to Stuttgart and presented their company on their marketplace.“ Companies are able here to gain an ideal overview of the innovations, trends and developments in their market environment. The trade fair location of Stuttgart is predestined for this. The region around the state capital of Baden-Württemberg has the highest industrial density in Germany and Europe. It is also home to one of the most productive clusters of tool, pattern and mould makers in the world. Southern Germany also contains a large number of traditional user industries such as plastic and metal working enterprises and automotive component suppliers.

The formative topics and trends during the four-day trade fair were very clear:
Nothing is preoccupying companies in the industry as much as digitalisation, an area which is posing great challenges for medium-sized enterprises in particular. This is also closely linked to the increasing internationalisation of business processes. During his tour of the trade fair Winfried Kretschmann, Minister-President of Baden-Württemberg, underlined the “impressive inventive and creative spirit” of tool, pattern and mould makers, and wished the companies courage on their road to the digital future. “It is easier to connect IT to our industrial world than the other way round. I know that tool, pattern and mould makers are stretched to the limit here, but also that they will achieve this objective.”

The exhibitors at MEX included many important companies who are assuming key roles in digitalisation with their products and services. Trade visitors were also able to obtain an extensive picture of the generative technologies, which are now changing the entire industry, and find out how 3-D technology and additive manufacturing methods can be integrated in their own process chains. Florian Niethammer, Team Director for Moulding Expo at Messe Stuttgart: “A large number of visitors to the trade fair came with specific requirements, even with project drawings, in order to discuss their concerns and problems on the spot with exhibitors. Intensive discussions were held and projects were also concretised right away. This represents something special.”

Exhibitors and visitors both rate MEX as positive
“Key to markets” is the motto of Messe Stuttgart. In the opinion of the exhibitors, this did not promise too much. They regard MEX as the perfect platform for the industry, and all of them awarded the trade fair good marks. Exhibitors unanimously mentioned good and lengthy business discussions. According to Franz Tschacha from the company Deckerform in Aichach, MEX is a “distribution and sales trade fair for German tool makers, which rightly exudes confidence.”
The participants were therefore confident that MEX will become even more relevant for the industry in future. MEX also went down very well with trade visitors: Out of the more than 14,000 visitors, 83 per cent said they would recommend the trade fair to other people while 93 per cent of them already knew that they would come back to the third edition of MEX in 2019.

Meeting point for an international industry network
One important task which was given to the MEX team by the advisory boards was to increase the internationality of the trade fair. “We are on the right track here,” said Niethammer. “The companies in which the visitors work come from Europe and all over the world.“ 31 per cent of exhibitors came from abroad – an increase of 7 per cent.

Theoretical and practical highlights in the extensive accompanying programme
Up to date and compact: first-class speakers provided insights into the important developments from the world of tool, pattern and mould making. “The seminars, talks and workshops were ideal occasions to exchange information, carry out further training and hold constructive discussions on technical topics. Experts from many different business areas in the industry met here,” said Florian Niethammer. Another highlight was the MEX special exhibition on the promotion of young people with detailed information on training and advanced training.

Outlook: after MEX is before MEX
No sooner had MEX 2017 finished at Messe Stuttgart, than the preparations for the third edition of the trade fair started. The trade fair organisers have resolved to continue establishing Moulding Expo as the leading European trade fair for the industry. “We are pleased that our still young trade fair is now already a permanent fixture in the calendar of European tool, pattern and mould makers,” said Ulrich Kromer von Baerle. He also clearly defined the next steps: “MEX 2017 has strengthened our conviction that we are on the right path together with the industry. However, organising trade fairs also means that we must continually develop and learn. We will therefore meet with the advisory board in autumn and determine the key topics and date of Moulding Expo 2019.“

Die optimale Lösung für hochpräzise Positionieraufgaben

Zykloidgetriebe von Nabtesco leisten nicht nur in Robotern hervorragende Arbeit, sie ermöglichen auch die exakte Positionierung von Rohlingen und Werkzeugmagazinen in Werkzeugmaschinen.

Die Zykloidgetriebe zeichnen sich durch eine sehr hohe Positioniergenauigkeit und Steifigkeit sowie eine besonders kompakte Bauform aus. Nabtesco bietet nicht nur diverse, in den Baugrößen abgestimmte Einbausätze mit und ohne Schrägkugellager an. Für Anwendungen mit geringem Bauraum finden Anwender außerdem zahlreiche Exzentergetriebe mit Hohlwelle im Produktprogramm: Hier lassen sich Datenkabel, Versorgungsleitungen oder Antriebswellen einfach und platzsparend durch die Mitte des Getriebes führen.

Dank der hohen Drehmomentleistungen, dem minimalen Spiel von weniger als einer Winkelminute und sehr hoher Steifigkeit sind die Zykloidgetriebe in der Lage, selbst hohe Traglasten ohne Nachschwingen schnell und präzise zu positionieren. Diese besonderen Eigenschaften verdanken die Getriebe ihrem Funktionsprinzip mit zweistufiger Untersetzung: Die doppelten Kurvenscheiben reduzieren die Drehzahl, so dass kaum Vibrationen entstehen. Da die Kraft sich durch die Rollen-Exzenter-Konstruktion zudem gleichmäßig verteilt, überstehen die Getriebe sogar eine Schockbelastung vom Fünffachen des Nenndrehmoments.

Getriebeserien für unterschiedliche Anwendungen erhältlich
Nabtesco fertigt verschiedene Baureihen seiner Zykloidgetriebe, die unterschiedliche Besonderheiten aufweisen. Die neuen RF-P-Einbausätze eignen sich z. B. ideal für den Einsatz in automatischen Werkzeugwechslern (ATC), da sie für Hochgeschwindigkeitsanwendungen auf engstem Bauraum konzipiert wurden. Speziell auf die exakte Positionierung von Magazinen in Werkzeugmaschinen sind dagegen die Getriebe der RA-EA/EC-Serie ausgelegt. Diese Ausführung hat eine sehr hohe Überlastfähigkeit, hohe Untersetzungen und eine angepasste Gehäuseform, die eine schnelle Integration in Scheiben- oder Kettenmagazine ermöglicht. Die ganzzahlige Untersetzung sorgt für eine punktgenaue Positionierung des Werkzeugwechslers.

Die RS-Serie findet häufig im Antrieb horizontaler Drehtische Verwendung. Diese hochpräzisen Hohlwellengetriebe mit integriertem Winkelgetriebe sorgen für die exakte Aufbringung von Schweißpunkten im Zehntelmillimeter-Bereich. Das RS-Getriebe ist für sehr schwere Lasten ausgelegt und kann dank seiner gusseisernen Basis einfach auf dem Boden montiert werden, so dass ein stabiler Stand gegeben ist. Die RS-Serie unterstützt Nenndrehmomente zwischen 2.548 und 8.820 Nm sowie Beschleunigungs- bzw. Bremsmomente bis zu 17.640 Nm. Das integrierte Hauptlager erlaubt den Einsatz in Anwendungen mit Axiallasten von bis zu 9 t.

Die RH-N-Baureihe ist aufgrund ihrer hohen Leistungsdichte besonders für hohe Traglasten geeignet. Das Getriebe lässt sich flexibel an alle marktführenden Servoantriebe anpassen und ist wegen seines innovativen Tribologiekonzepts extrem wartungsarm. Da Antriebsritzel und ein Motorflansch für die gängigsten Motortypen in den Getriebekopf integriert sind, kann der Konstrukteur das Getriebe einfach per Plug-and-Play in die Anwendung einsetzen.

Die Freiheit des Bohrens

Iscar hat die Bohrer-Linie Sumocham12xD-Bohrkörper mit Durchmessern von acht bis 11,5 Millimeter erweitert. Die Werkzeuge überzeugen unter anderem durch lange Standzeiten und eine sehr gute Spanabfuhr. Anwender haben damit einen größeren Arbeitsspielraum bei anspruchsvollen Bohranwendungen.

Bei den selbstzentrierenden Geometrien HCP-IQ kann unter optimalen Bedingungen auf eine Pilotbohrung verzichtet werden.

Zusammen mit den bereits bestehenden Grundkörper-Varianten (1,5xD, 3xD, 5xD und 8xD) steht dem Markt somit ein vollständiges Produktportfolio für einen Bereich von acht bis 25,9 Millimetern und einer Bohrtiefe bis 12xD zur Verfügung.

Die Bohrer sind stabil geklemmt, wodurch die Prozesssicherheit erhöht wird. Das Werkzeug besitzt eine innere Kühlmittelzufuhr mit gedrallten Kanälen, die effizient direkt an der Bearbeitungszone wirkt. Der Zylinderschaft ermöglicht eine optimale Rundlaufgenauigkeit. Damit erreicht der Anwender eine sehr hohe Oberflächengüte.

Die Bohrkörper verfügen über große polierte Spankammern und gewährleisten eine exzellente Späneevakuierung bei allen Werkstückstoffen. Das innovative selbstklemmende und selbstzentrierende Bohrkopf-System erzeugt eine sehr hohe Stabilität und ist sowie einfache und sicher zu handhaben – selbst beim Wechsel der Bohrköpfe in der Maschine.

Für höchste Leistungsfähigkeit bei allen Werkstückstoffen bietet ISCAR drei optimierte Bohrkopf-Geometrien (ICP, ICM, ICK) mit angepassten Anschliffen. Zusätzlich erhältlich sind Bohrköpfe mit vier Führungsfasen oder selbstzentrierende Geometrien, die dem Anwender eine maximale Bohrungsqualität bezüglich Fluchtungsgenauigkeit, Koaxialität und Positionsgenauigkeit bringen. In der Praxis bedeutet dies gleichbleibend optimale Bearbeitungsergebnisse.

Die neueste Entwicklung für produktives 12xD Bohren sind die Bohrköpfe der HCP und QCP-2M Linie. Bei diesen Geometrien kann der Anwender unter idealen Bedingungen auf eine Pilotbohrung verzichten und dadurch die Produktivität um bis zu 30 Prozent steigern.

CGTech présentera la version de VERICUT 8.1 de à EMO

CGTech montrera sa dernière version de VERICUT 8.1, son logiciel de simulation des machines-outils à commande numérique CN, vérification et logiciel d’optimisation à l’exposition d’EMO à Hannovre, Allemagne, du 18 au 23 septembre, Hall 25, stand D07.

VERICUT 8.1 apporte de nouvelles fonctionnalités : amélioration du module d’optimisation Force™, un nouveau module de fabrication additive, section de la pièce, mesure « X-Caliper », matrices de rapports ainsi que les opérations de dressage et de rectification.

Vericut Forceoptimise les programmes de commande numérique en analysant les conditions de coupe telles que les efforts, l’épaisseur copeau et les vitesses d’avance. Dans cette dernière version, Force peut afficher des graphiques et des diagrammes en temps réel des conditions de coupe et efforts tels que rencontré par l’outil de coupe. Cette caractéristique permet au programmeur de CN d’identifier très rapidement des conditions défavorables telles que les efforts excessifs, épaisseur copeau et flexion outil par simple visualisation graphique. L’optimalisation des efforts et de l’épaisseur copeau réduit le temps de production, augmente les durées de vie des outils et engendre des états de surface de plus de haute qualité.

Le module additif permet la simulation des machines CNC d’impression 3D par dépôt de poudres métalliques. Vericut lit les paramètres laser, contrôle la puissance du laser, le flux de gaz porteur et le dépôt de poudre métallique spécifique à chaque type de travail et matière. Avec la technologie de modélisation de gouttelettes, le modèle additif de Vericut est beaucoup plus qu’un simple «matériau déposé». Chaque cordon contient son historique d’information. Cela permet de retrouver rapidement les erreurs, les zones vides ou les zones de matière mal placée. L’origine de la mal façon étant révélée en un seul clic.

La nouvelle boite de dialogue des sections de Vericutpermet de voir à l’intérieur d’une pièce plus facilement  et plus rapidement pendant la simulation. Ceci permet à l’utilisateur d’identifier et vérifier les interférences entre la pièce et les composants de machine. L’outil de mesure de « X-Caliper » identifie les dimensions géométriques de la pièce. Dans la version 8.1, les mesures sont affichées sur la pièce et suivent la pièce avec son évolution.

Les  opérations de rectification sont améliorées avec le support des opérations de dressage. Vericut peut également simuler la compensation dynamique même quand la meule est engagée dans la pièce.

Au sujet de CGTech
Le Logiciel Vericut de CGTech est le leader de la technologie des logiciels de simulation, de vérification et d’optimisation de machines CN. Depuis 1988, nos produits ont atteint le rang de standard des secteurs industriels dont l’aérospatiale, l’automobile, les transports terrestres, le moule, les produits grand public, la production d’énergie et l’industrie lourde. Aujourd’hui, avec des bureaux en Europe et en Asie et un réseau mondial de revendeurs, les logiciels CGTech sont utilisés par des entreprises de toutes dimensions, des universités, des écoles et des organismes gouvernementaux.